Public Will Have To Wait For Bay Bridge Welding Report

The latest on the Bay Bridge welding scandal...

According to NBC channel 11, Caltrans (the Bay Bridge Contractor) is not expecting results from last week's Bay Bridge inspections until next week. Inspectors with the Federal Highway Administration began testing welding work on the project after former welders said they were forced to do shoddy work.

Inspectors are still examining steel samples they removed from the bridge at a laboratory in Washington. The contractor has begun repairing the damage done to the bridge during the testing process.

Welding Industry Wins Texas Trial (from Businesswire)

HOUSTON & WASHINGTON--(BUSINESS WIRE)--April 29, 2005--John Beisner, attorney for several current and former welding rod manufacturers, today issued the following statement regarding the defense verdict in the Presler case, which was returned today after a three-week trial in Brazoria County, Texas:

"The industry is extremely pleased with the verdict in this case. Today's decision further illustrates that there is no causal link between mild steel welding and Parkinson's disease or any other Parkinson's-like movement disorder, and that these cases are entirely without merit.

"Judges and juries across the country have overwhelmingly rejected these claims, and the welding industry will continue to defend itself vigorously against these suits. Of the nine cases tried to verdict before this case, eight resulted in defense verdicts. When this case was originally tried in February 2005, the jury was unable to find a link between the plaintiff's condition and his welding activity; a mistrial was declared as a result of a hung jury. The jury in this case returned with a defense verdict in a matter of hours.

"The fact that the plaintiffs were unable to win their banner case --which was tried by the renowned plaintiff's lawyer Mikal Watts, in a "magic" jurisdiction, with a sympathetic plaintiff -- shows that welding fume litigation does not hold much promise for the plaintiff's bar. Despite all their hype, plaintiffs cannot establish causation in these cases, because it just isn't there."

Lead defense trial counsel in the Presler case was John Bissell of Strong Pipkin Bissell & Ledyard, L.L.P.

And more on this one...(from the welding rod litigation network)

The industry is extremely pleased with the verdict in this case. Today’s decision further illustrates that there is no causal link between mild steel welding and Parkinson’s disease or any other Parkinson’s-like movement disorder, and that these cases are entirely without merit. Judges and juries across the country have overwhelmingly rejected these claims, and the welding industry will continue to defend itself vigorously against these suits.
Of the nine cases tried to verdict before this case, eight resulted in defense verdicts. When this case was originally tried in February 2005, the jury was unable to find a link between the plaintiff’s condition and his welding activity; a mistrial was declared as a result of a hung jury. Despite all their hype, plaintiffs cannot establish causation in these cases, because it just isn't there.

A substantial number of these cases are now part of a federal multi-district litigation (MDL) in Cleveland. The MDL Court in Cleveland will be the first court to conduct a full and fair hearing on the scientific validity of the plaintiffs’ theories in these cases. We believe that the real truth about the lack of merit of these claims will be exposed in that venue.

For a complete analysis of the existing body of science and theories, please see a recent report by Dr. David Garabrant, Professor of Occupational Medicine and Epidemiology at the University of Michigan School of Public Health. At the end of this detailed report, Dr. Garabrant concludes that a review of the medical and scientific literature does not reveal any reliable association between welding fume exposure or manganese with Parkinson’s disease.

Welding Vs. Brazing

When it comes to creating strong, permanent metal joints, two methods--welding and brazing--usually have to duke it out. Let the sparks fly:

When you want to join metal parts, you can choose from several options--including adhesive bonding and mechanical fasteners--but when you want to create robust, permanent metal joints, you typically have only two choices: welding or brazing. While welding creates metal joints by applying concentrated heat at the joint to melt and fuse metals together, brazing involves significantly lower temperatures and does not entail the melting of base metals. Instead, a filler metal is melted and forced to flow into the joint through capillary action. (Welding usually adds a filler material as well.)

In welding and brazing, the strength of the joint often surpasses that of the base materials. But because the heat used in brazing is less intense, this process does not alter most physical properties and minimizes distortion, warping and stresses in the joint area. Additionally, brazing's lower temperatures translate to less energy requirements.
But of course, the decision to weld or to braze comes down to the specifics of the application.

Here are the factors to consider:

• Size of the assembly: If you want to join large assemblies, welding is the more appropriate method. The tendency of larger assemblies to disperse heat can be a stumbling block for brazing, making it hard to reach the temperatures required for the filler metal to flow. In contrast, the concentrated heat of welding and its ability to trace a joint allow it to excel in joining big assemblies.
• Thickness: Both methods are sound choices when metal sections are on the thick side, around 0.5 inches or more. Brazing has the edge, however, when it comes to thin sections. The high heat of welding can warp or burn through such sections. In contrast, brazing can help you avoid distortion.
• Shape of joint: While both welding and brazing can create spot joints, the localized heat of welding offers the advantage of speed and low cost. However, when it comes to linear joints, the manual tracing required by welding makes it the less convenient choice. Additionally, brazing can just as easily draw the filler metal into straight, curved or irregular joint configurations.
• Types of materials: Brazing soundly beats welding when joining dissimilar metals. As long as the filler material is metallurgically compatible with both base metals and melts at a lower temperature, brazing can create strong joints with barely any alteration of the base metals' properties. In contrast, base materials are melted during welding so joining two dissimilar metals using this method can entail complex and costly techniques.
• Production volume: In manual jobs, the above factors--size, thickness, shape of joint and materials--will guide your decisions, but when part volumes are in the hundreds or thousands, production techniques and cost will become the most important considerations. While both brazing and welding can be automated, brazing allows for more degrees of automation. With welding, you're usually forced to choose between two extremes--either weld manually, one by one, or use pricey, cutting edge equipment for large runs. In contrast, brazing can support medium-sized runs.
• Appearance: With a neat and discreet strip, brazed joints are generally more attractive than welded ones, which have non-uniform beads. The vast majority of the time, you won't need additional finishing operations after brazing.
  

Source:
When Brazing Beats Welding Steve MarekMachine Design, December 9, 2004,

Welding fumes lead to workers' comp claims

More from the Bay Bridge scandal. This to do with Fumes and worker's health, from the San Mateo County Times (Full Story here)

For about a year, Lupe Gaytan climbed up and down the 50-foot cofferdam ladders to weld inside the steel legs of the partially built Bay Bridge. When he started, his lungs were fine, he said, referring to a piece of paper indicating he was healthy enough to be fully cleared to use a safety respirator while welding on June 19, 2003.

Today, Gaytan climbs into bed every night and straps on a mask that helps him breathe while he sleeps. The Union City man said he never had such problems before he worked on the Bay Bridge.

``I don't smoke,'' the 49-year-old Gaytan said. ``Now I've been diagnosed with restrictive pulmonary disease.''

Gaytan and more than a dozen other current and former welders on the bridge job came forward after an Oakland Tribune report in June showing the contractor for more than a year knowingly exposed workers welding particulate and fumes, including manganese, in excess of Cal-OSHA standards. Cal-OSHA records show prime contractor KFM Joint Venture didn't tell the workers about the overexposure, require respirators or fix the problem.
Now dozens of welders have filed worker's compensation claims - which were denied and are on appeal - based on the exposure. They say a class-action lawsuit is in the works.

(See link above to read the entire story). I think we're seeing the issues bad planning and poor execution can bring up for contractors. If you're a welder, never let your health get in the way of work. It's not worth it...

Airgas Announces Letter of Intent to Acquire Industrial Products Division of LaRoche Industries

RADNOR, Pa.--(BUSINESS WIRE)--April 26, 2005--Airgas, Inc. (NYSE:ARG) today announced it has signed a non-binding letter of intent to acquire the Atlanta-based Industrial Products Division of LaRoche Industries, a leading distributor of anhydrous ammonia and related services in the U.S. The companies expect to sign a definitive asset purchase agreement shortly and close the transaction at the end of May, subject to customary closing conditions.
The acquisition would include a nationwide distribution system of 24 locations and more than 100 delivery vehicles. The business to be acquired generated about $65 million in revenues in 2004 and employs more than 130 people. The acquisition is expected to be accretive in the first year.

"This operation is a good strategic fit with our distribution infrastructure and would greatly strengthen our process chemicals platform acquired from Air Products in 2002," said Airgas Chairman and Chief Executive Officer Peter McCausland. "The LaRoche assets would broaden our infrastructure to include railcar distribution, which could be used for transportation of other products in our portfolio. Its primary customer base in the utility industry also fits well with a key industrial market for us."

The acquired operations and related personnel would become a new business unit, Airgas Specialty Products, within Airgas' Gas Operations Division and accounted for with the All Other Operations segment in its financial results. The Gas Operations Division also includes Airgas Carbonic and Dry Ice, Airgas Nitrous Oxide, and Air Separation Unit operations.
"Upon a successful closing, the people of the Industrial Products Division of LaRoche can look forward to a stable and prosperous future as a member of the Airgas family," said Michel Rapoport, president of LaRoche Industries. "Our organization looks forward to working with Airgas on a smooth transition for our customers, who should see continued great service for their ammonia and related needs."

About Airgas, Inc.
Airgas, Inc. (NYSE:ARG) is the largest U.S. distributor of industrial, medical and specialty gases, welding, safety and related products. Its integrated network of about 900 locations includes branches, retail stores, gas fill plants, specialty gas labs, production facilities and distribution centers. Airgas also distributes its products and services through eBusiness, catalog and telesales channels. Its national scale and strong local presence offer a competitive edge to its diversified customer base. For more information, please visit www.airgas.com.

Bay Bridge welding case losses from ContraCosta Times

Some wise words on the Bay Bridge welding scandal...

"No matter the outcome of the Bay Bridge welding case, the public gets hurt. If the welders who say shoddy workmanship has been accepted and even encouraged turn out to be genuine, the loss is obvious. That finding will be financially costly at this stage in building the new eastern span of the bridge, but it could have been even more costly if a cover-up continued. Lives would have been at stake. Somewhere in the future a section of the Bay Bridge crumbling would have undoubtedly been deadly.

These whistle-blowing welders will be heroes, if they have prevented tragedy. We will be left with a sickening realization that some people would chance the safety of millions, including probably their family's for generations to come. And for what? To save money now, money that will be spent multiple times over for new repairs. The lack of concern for the many and the future in such a scenario is appalling."

Read the rest of it here...

Welder sparks fire at Pittsburgh Zoo

Here's a cautionary tale about fire safety and welding...

PITTSBURGH (AP) — A welder sparked a fire Monday at the Pittsburgh Zoo in a nonpublic building that houses two apes, which were not injured.

The fire started at about 9:15 a.m. in the winter animal holding area. The animals, two mandrills, were quickly removed, zoo officials said.

No workers or animals were injured.

The fire was began when a welder touched insulation in the walls, sparking the fire, which spread to the roof.

The zoo remained open for visitors.

Welding Encyclopedia online from Welder's Corner

We've recently added a Welding Encyclopedia to the Welder's Corner. It's based on the great, free online resource, the Wikipedia. The encyclopedia breakes welding down into its core components and explains everything in detail.

The Wikipedia, a "user created" common pool of knowledge, is a terrific resource for topics of all kinds. It's created by people with an interest in the topic, and you can add, edit,. or change categories. It's communal knowledge of the best kind for just about any topic.

Check it out:

• Welder's Corner Welding Encyclopedia.
• Wikipedia

Welder turns hobby into business

Carl Jenkins has been welding since he was in junior high school.
"I was hooked on welding when I made a rod-iron lamp in the seventh-grade industrial arts class," recalled Jenkins, 60, who grew up in Ohio but moved to Canton three years ago.

Now, nearly 50 years later, he has turned that passion into a unique craft business.With the help of technology and his girlfriend, Mary Ann Sanderson, Jenkins has started Carl's Mobile Welding and Metal Craft Fabrication Creations.

Jenkins and Sanderson use a computer program and a plasma cutter to create custom-made works of art out of steel.They started their part-time business in 2003 with the purchase of a TorchMate CNC plasma cutter. A plasma cutter works by sending an electric arc through a gas that is passing through a constricted opening. That elevates the temperature of the gas to the point it becomes plasma, which is used to make clean, precise cuts.

Read the article - are you interested in turning welding into your career, if it isn't already? I suspec that there is a good niche for this kind of service...

Grand jury investigates allegations that Bay Bridge welders concealed faulty welds

The Bay Bridge welding saga continues...This will be interesting to watch.

Caltrans has handed over hundreds of thousands of pages of records to a federal grand jury, which is investigating allegations that welders concealed faulty welds on the new Bay Bridge.
The federal subpoena of Caltrans documents was first reported on April 8, but records obtained Thursday under the California Public Records Act show for the first time the role of a federal grand jury and the wide net cast by investigators.

In addition to 330,000 state welding inspection records, federal prosecutors are seeking numerous Bay Bridge contract documents, payroll records from prime contractor KFM Joint Venture, Caltrans personnel records and a variety of correspondence to and from "inspectors and officials involved in the welding process." Prosecutors want records back to the 2002 start of the $1.5 billion job to build a concrete skyway. Welding records fill 80 boxes and three metal construction huts.

Bay Bridge Welding Saga Continues: Sections To Be Cut Out For Tests Of Welding Work

Well, it continues out in Oakland...

Inspectors hired by the federal government will be cutting out some large sections of the steel foundation work on the Bay Bridge to test the quality of its welding work. A Caltrans spokesman says that several 300-pound sections of the foundation will be removed during the next few days and shipped off to a special lab for tests.

Officials don't know when the results from the inspections will be complete.
The tests are part of an investigation over allegations by former welders that some of the welding work is faulty. The contracting company that did the work and Caltrans deny there are any problems with the quality of the welds....

Multimatic wins PACE Award with Sophisticated Welding Process

They're always pushing the envelope. I've said before that welding is perhaps the most overlooked manufacturing process around, and here it is in a super sophisticated, highly effective application.

Multimatic wins 2005 Automotive News PACE Award

Multimatic has been named as a 2005 Automotive News PACE Award winner - recognizing the Toronto-based company as key automotive supplier for superior innovation, technological advancement and business performance.

Multimatic received the award in Detroit on April 11 for its new proprietary I-Beam Control Arm Technology which was introduced on the 2005 Ford Mustang.

This unique vehicle suspension member is configured to utilize two complex press formed stampings, welded together to form a highly efficient I-beam cross-section.

An I-beam is the most structurally efficient section for a MacPherson strut suspension arrangement. The truly innovative aspect of the Multimatic technology is that each stamping is configured with the correct plan view shape and is formed into a U-shaped section with the upstanding flanges fully returned 180 degrees back upon themselves to effectively double their thickness.

This requires highly sophisticated metal forming techniques to fold the edges back into a double material thickness upstanding flange, especially around the tight radii dictated by the plan view shape. The two stampings are then placed together in a back-to-back arrangement and welded along the free, peripheral edge using a novel and proprietary gas metal arc welding process.

Read more...

"The FHWA inspection found that there were no faulty welds last week, and we are confident that the same conclusions will be reached''

More on the Bay Bridge Welding Scandal...

Two more inspectors arrived today to "double- and triple-verify'' the safety of welds on the new eastern span of the Bay Bridge, the California Department of Transportation announced today.

Caltrans officials asked the Federal Highway Administration to bring in independent inspectors while the FBI conducts its own investigation into allegations of substandard welding work on the skyway.

"The FHWA inspection found that there were no faulty welds last week, and we are confident that the same conclusions will be reached'' by the independent inspectors, Caltrans spokeswoman Lauren Wonder said this morning.

She described the effort as "a third-party inspection to just double- and triple-verify'' that the welds are safe.

The inspectors are Mike Mayes, owner and president of Mayes Testing Engineers in Everett, Wash., and metals consultant Roy Teal of Albany, N.Y., Caltrans reported. Their work begins today with safety training on the bridge construction site.

Wonder said it's not clear how long the independent inspection would take, but the results would likely be made public quickly.

"We have confidence (in the welds) and it would behoove us to make an announcement,'' Wonder said.

High School junior sets sights on national title with his welding skills

From the Lufkin, Texas Daily News...

For the average “shop” student, taking a high school welding class rarely involves more than showing up for class and getting one's hands dirty along the way. On very few occasions is the student required to stand before an audience and demonstrate his or her abilities in this chosen endeavor. However, the occasion sometimes arises when the young man or woman is called to show off some serious skills.

Kenny Burch, a Lufkin High School junior, recently traveled to Fort Worth to participate in Job Skill Demonstration competition comprising high schools from 13 Texas school districts. At the convention, students were required to give a demonstration of their various job skills, with the hopes of bringing home a gold medal for a first-place finish.

Apparently, Burch is a welding fool. With instructor Jerry Taylor urging, “Git 'er done,” Burch brought home the gold, along with some praise from the judges.

“The judges told me that I have the potential to win nationals,” Burch said. “They're expecting me to take gold there as well.”

Burch's competition required him to offer a five- to seven-minute demonstration of welding skills used “in the field.” Competitors were judged by three separate judges in such categories as quality of presentation; vocal abilities, including levels and clarity; and how well the demonstration was put together.

Burch, a second-year welding student at LHS, demonstrated his abilities in oxyacetylene welding and cutting equipment. His project included identifying cylinders, regulators, hoses, cutting head attachments and various tips. Some of his competitors offered demonstrations in such life skills as Cosmetology and Culinary Arts.

Burch said he first developed an interest in welding in his sophomore year, when his father, Kenneth Sr., suggested that the younger Burch give it a shot. The elder Burch offered advice based on his own experience as a welder, and the son responded by enrolling in the class.

Over the past two years, Burch has worked in various areas of the welding skill, including “mig,” a technique in which the welder is using only copper wire instead of an electrode, or “stick.” Burch has also worked on a transportable barbecue pit, as well as other projects.

Burch, who works as a lifeguard during the summer, sees his welding prowess as a potential ticket to college. He hopes to attend Lamar University in Beaumont, or possibly Texas A&M, where he will “branch out” his goals and interests. Eventually, he would like to land a job working pipelines or offshore.

“I know the money is great for this particular occupation — sometimes as much as $60 an hour,” Burch said. “Hopefully, what I'm learning now will put me in the position to make that kind of living.”

Bay Bridge welders' gripes fell through the cracks

In the continuing story of the Oakland Bay Bridge Welders scandal, the bad news just keeps coming. One thing's clear: something wrong was going on at that project.

"Cal-OSHA inspectors failed to investigate fully a formal complaint made in late October alleging continued exposure of excessive manganese and other welding fumes to Bay Bridge workers.

In June, a Cal-OSHA letter to contractor KFM Joint Venture stated that workers had been exposed to similar conditions, which KFM Joint Venture knew existed, for more than a year.

The second complaint, in October, made by seven current and former workers, sat for about three months because of the original investigator's job reassignment, said Cal-OSHA spokesman Dean Fryer, adding that the allegations were not considered an imminent hazard.

The investigation was picked up in January when a new Cal-OSHA investigator asked one of the complainants, who had since been laid off, to track down information about conditions on the job site, Fryer said.

The investigator wanted more information about what type of welding the worker. were doing to determine if they were using equipment known to create the excessive fumes and particulates, the spokesman said. Automated welding exposes workers to more fumes than other types of welding, Fryer said."

In a June letter to Cal-OSHA, Kiewit denied workers were consistently exposed to excessive welding fumes and particulates.

From the "some welding jobs are more important than others" file...

Norshipco welders take leave to weld armor onto combat vehicles

NORFOLK, Va. Some of Norshipco's welders are taking a leave from working on Navy ships to work on an Army contract.

About 25 welders a day are putting together armor for combat vehicles in Iraq and Afghanistan. The Army awarded the contract to Norshipco's parent company, United Defense Incorporated. The armor cages are meant to guard tanks from rocket-propelled grenades. The work should continue through the summer.

One-armed man learning to live again - by welding

What an inspiration...

Brandon Whatley lost his arm in a car accident, but he's working hard to learn the welding trades. Here's to his future.

"A shower of sparks cascades like white-hot rain as Brandon Whatley stares intently through the visor of his face shield. Chest braced against an angle iron, his gloved left hand gripping an electrode holder, Whatley is arc-welding a vertical bead along the joint between two plates of 3/8-inch steel.

Like the other students in his welding class at Central Georgia Tech, he's not having an easy time. "It should look like a row of dimes," he mutters, pulling back from the workpiece and lifting his visor.

But the joint is lumpy.

Whatley grew up right-handed, but he now works exclusively with his left. The right sleeve of his work shirt hangs empty. Unlike the other students in his welding class, Whatley has no right arm..."

Welding is hard enough with two arms.

Asbestos, Mesothelioma, and Welders

Since asbestos was used in so many ways, for so many years, in so many places, welders have been among those most affected by its ill effects, including mesothelioma, commonly known as asbestos cancer.

Most construction or fabrication workers were involved with asbestos at some time or another, even those of the unlikeliest professions. Asbestos was used in shipyards, petrochemical plants, paper mills, factories, steel mills, building construction, and the telephone industry. Asbestos was used so widely that virtually all that was involved with construction or design, of any kind, had exposure to asbestos in one form or another.

In particular, welders who work on renovation projects are at risk, and if you do, you should be aware of the dangers.

According to AsbestosResource.com, "building engineers, building material products manufacturers, cement plant production workers, construction workers (including insulators, boilermakers, laborers, steel/ironworkers, plumbers, steam fitters, plasterers, drywallers, cement and masonry workers, roofers, tile/linoleum installers, carpenters, HVAC mechanics and welders) all used asbestos in many products that they worked with. Asbestos was used in the flight industry, so aerospace and missile production workers, aircraft manufacturing production workers, and aircraft mechanics are all at risk. Basically all trades of construction workers are at risk."

What does this mean to welders working today? For the most part, we're safe, as companies are cognizant of the dangers of asbestos exposure and mesothelioma. But do you really want to leave your safety to someone else? If you are working in an old facility, where there might be some possibility of asbestos being present, don't be afraid to ask questions.

It's your health, after all.

Man copes with painful disease: manganese poisoning

Everyone involved in the welding business, from fab shop operators to manufacturers to guys welding on the line, needs to understand what's at stake with manganese poisoning.

Here's one man's story...

Lying flat on the bed in his apartment, Fisher, of Olney, described his pain and how Parkinson's disease has taken away his ability to live a normal, independent life and how it has caused a strain on his family and other relationships.

"It's very frustrating," he said, careful not to become too excited because stress accelerates the pain that he described as "sharp, crampy."

Joe Fisher recently laid in bed in pain on a warm spring afternoon, trying to deal with a disease that has plagued him for nearly a decade as he struggled through a day that was hardly going well.

Lying flat on the bed in his apartment, Fisher, of Olney, described his pain and how Parkinson's disease has taken away his ability to live a normal, independent life and how it has caused a strain on his family and other relationships.

"It's very frustrating," he said, careful not to become too excited because stress accelerates the pain that he described as "sharp, crampy." Joe has been living with Parkinson's since he was 43 years old and an employee of Caterpillar Corporation in East Peoria. He had to stop working as a welder in 1998 after 23 years with the company. He learned he had manganese poisoning, which is thought to have happened during his time as a welder.

Look, nobody knows for sure what drives these cases. If you're in this business, follow every safety guideline for ventilation and handling of rods. America is built on welded metal, but we need to be sure the welders are safe.

California Attorney General Launches Civil Probe of Bay Bridge Welding...

I posted about this a week or so back, and it appears to be back in the news. From CBS 5 in Oakland, California... This story is worth watching, considering the potential problems they could face with up to five thousand bad welds on something as vital as that bridge.

The California attorney general's office reported today it has launched a civil investigation into allegations of flaws in the welding on the new eastern span of the Bay Bridge. Tom Dresslar, a spokesman for Attorney General Bill Lockyer, said the probe is a false claims investigation that will try to determine if taxpayer funds were unlawfully obtained through fraud or deceit.

Dresslar said the attorney general's investigation is separate from a criminal probe being conducted by the FBI into allegations by current and former bridge welders. The workers have claimed that as many as one third of the 5,000-plus welds they put in place on the span were faulty and that bridge contractor KFM told them to cover up shoddy work.

Dresslar said if his office finds wrongdoing, it could seek civil penalties, actual damages and triple damages.

He said the probe began this week and "we'll take as long as we need for a thorough investigation.''

Dresslar said that after the attorney general's office became aware of the allegations of shoddy welding on the bridge, the office had an internal review and discussions and decided that a civil investigation into the possibility that taxpayer funds were spent under false pretenses would be the most appropriate avenue for it to pursue.

Caltrans officials weren't immediately available for comment on the investigation by the attorney general's office. Last week, Caltrans Director Will Kempton said the agency has "a great amount of confidence'' in the quality of the welding."

Production Monitoring Software from Lincoln Electric Enables Remote Weld Data Review

This is a press release from Lincoln Electric.

Cleveland, Ohio - Whether on the road or in the office above the factory floor, new Production Monitoring™ Software from The Lincoln Electric Company enables key personnel to monitor weld data for any networked Power Wave® power source at the touch of a button. Allowing engineers and executives to stay connected with the shop floor from anywhere in the world helps to ensure welding systems are working properly and identifies problems as they arise.

In addition to monitoring weld data, the Production Monitoring Software allows for storing and sharing files, monitoring production tasks, setting weld limits and tolerances, and tracking consumable inventory. With Lincoln's new software, welding machine faults can also be logged and emailed, while diagnostic troubleshooting can be performed from a remote location.

By integrating digital technology to network welding equipment, key personnel will be able to perform the following functions from anywhere in the world:

• Easily set welding limits based on sampling with the Installation/Set-up Wizard.

• View the status of multiple networked Power Wave welding power sources at the push of button.

• Collect and store long and short term weld history.

• Execute actions or develop communication alerts when out of limit.

• Pinpoint work shift problems and evaluate production cycle and output using work shift timers and production reports.

• Manage and set tolerance data for each of 32 unique weld profiles.

• Email data to multiple users to provide information on specific events, potential or real-time problems.

• Automatic wire usage tracking and notification to minimize downtime for consumable replacement.

• Generate power source performance reports.

Lincoln Electric is the world leader in the design, development and manufacture of arc welding products, robotic arc-welding systems, plasma and oxyfuel cutting equipment.

Mig welding and auto body work - when to use MIG, Hammer Welding, or Tig Welding

Do you use MIG welding for auto body work? (Full credit: See this article for more info)

It’s been called a “bad idea fostered on us amateurs by our ignorance.” This is because using MIG on auto body work is akin to using a sledge hammer to hammer in finishing nails—it’s too rough for the work.

If you look at the available wire for MIG, you don't find anything much softer than S60 or higher wire. In general, the higher the yield strength of metal, the harder it is to work. So the weld bead left by MIG is extremely hard relative to body sheet metal. It’s almost impossible to work in that context. It also cracks very easily even if one tries to anneal the metal in the weld. “In restoring a 1967 Mercury Cougar I finally had to teach myself hammer welding using a welding torch,” said one welder. “The results were better!” This welder taught himself hammer welding using a welding torch. When he did…

• The seam is the same thickness as the parent sheet metal.
• The seam is as soft or softer than the parent sheet metal.
• The seam and the surrounding sheet metal are easily worked to remove any defects caused by the welding process.

Should you want to equal the hammer welding process but with an electric source of heat, TIG welding is the way to go. The filler metal selection is lots wider and the TIG can be run way down to 10 amps or so which would probably let you weld aluminum foil! Most professional welders hold the opinion that a TIG weld is superior to MIG.

So why do professional body shops use MIG? Mostly because it’s necessary for welding high-strength steel used in the structural automobile parts, but not for external sheet metals. External sheet metal—the part of the car we can see—is mild steel It’s too expensive and difficult for car manufacturers to make sheet metal forming dies with high-strength steel. Body shops replace whole panels. They rarely patch one. The high-quality restoration shops use TIG or (usually) a torch and hammer welding.

How to build your own welding table for about $50...(from Lincoln Electric)

A great little resource is available over at Lincoln Electric...how to build your own Welding Table.

A steel welding table is a basic necessity for any welder's workspace, since welding on a wooden surface can present a very real fire hazard. In addition, with a steel table, the welder's work clamp can be attached to it, and parts placed on the table will be electrically connected with the table's surface. This provides the advantage of keeping the work clamp and its cable out of your way while welding. Finally, building your own welding table with allow you to stand upright and place smaller projects at the right height for welding.

Following are instructions for building your own metal welding table. All of the items, with the exception of the metal plates needed for the shelves, can be found readily available at your local home improvement store. The steel plates can be purchased from a local steel supplier easily found in your local yellow pages. Expect to complete this project in less than four hours. The estimated cost for the materials to build this welding table is $50.

Lincoln gives you a lot of information on how to do this welding table project. They have photos, extensive information, and even plans in PDF format. You should check it out; it sounds like a fun project.

Students practice motor skills with Welding

The work is tedious, the hours long, the dirt unending and the pay nonexistent; but for the love of cars, 14 high school students work day in and day out to fulfill every teenager's dream of someday driving a hot rod.

Okay, so maybe they're not all hot rods, but the students in the Regional Occupational Program (ROP) Auto Body Paint and Repair course at Paradise High School are working on cars because it's what they love to do.

In the ROP auto class, students learn skills such as welding, painting, sanding and dent removal to prepare them for a job in the automotive repair field, if they so desire, or just for their own, personal knowledge and enjoyment.

Compared to welding under a bridge, this sounds like fun!

MIG welders: Machines for the modern farm shop

Good information for agricultural welders here:

David Anderson of Hobart Welders says he’s talking to more farmers who are interested in buying a MIG welder for machinery repairs.

Why? Compared to a stick welder, a wire-feed MIG can weld thinner material (22 to 24 gauge) and can be used with a shielding gas for better puddle control and bead-wetting action. In addition, Anderson says MIG is an easier welding process to master. “After a few hours of practice, even a novice can create good-looking weld beads with a MIG welder,” he says.

Buying tips. For a high-quality MIG welder that runs on 115v household current, expect to pay between $400 and $600. These all-in-one MIG welding machines should come almost ready to run out of the box. “Be sure to buy a machine with a built-in gas valve and a regulator. Some ‘wire welding’ machines designed for gasless flux cored welding are sold without them,” Anderson says.

Ohio State offers welding engineering course of study - worldwide...

Interested in becoming a welding engineer? It can be done - even if you don't live near a goo d program - with the OSU welding engineering program. The program's designed to train welding engineers to meet the challenges of manufacturing for the 21st century. It's the only ABET accredited undergraduate program in North America

Welding is a critical manufacturing process that has been estimated to impact over 50% of the products manufactured in the U.S. Almost every segment of our economy depends, to some degree, on welding and materials joining. While most may think of welding in terms of a process, it is actually a complex engineering discipline that involves aspects of materials science, design, inspection, mechanical and electronic systems, lasers, and robots.

The Welding Engineering Program at Ohio State University supplies top-notch welding engineers to the worldwide manufacturing community. According to their site, "In order to expand the availability of a Welding Engineering education to a wider audience, the faculty has embarked upon a distance education program to allow students from around the world to access Welding Engineering courses at both the undergraduate and graduate level."

These courses can be taken on either a credit or non-credit basis. The following provides additional information on undergraduate and graduate courses that are being offered via distance education, a schedule for course offerings, and an on-line M.S. Welding Engineering degree program.

Interesting stuff, for sure, and worth checking out if you're interested in advancing your career.

Hot, stifling quarters make checking on welders tricky

Wow. Some of the toughest welding conditions in the world are at Oakland's Bay Bridge. Bay Bridge welders work under tough conditions where, in cramped, hot quarters, it's easy for a fatigued worker to make everyday mistakes. Check out what these guys have to endure to work on the bridge...

• Because the only way to reach these underwater metal chambers is by boat and ladder, it can be tricky for quality-control inspectors to watch for errors.<>
• <>For 10 hours a day, welders stand in an area the size of a walk-in closet, moving a Bug-O welding robot in preset zigzag patterns as much as 50 feet below the Bay waterline.
• Metal is preheated to 250 degrees Fahrenheit, so the chamber is not just smoky, it's hot. One welder took a thermometer into the hole and said it topped out at 135 degrees.
• A person who turns his back on welding can get sunburn-like radiation burns on his neck after five minutes, instructors say.
  
• Welders lost several pounds of water weight just standing in "the hole" each day.
  
• Strong men in their early 20s are so drained they take catnaps in uncomfortable nooks, even after taking potassium tablets and guzzling Gatorade.
  
• On the Bay Bridge job, one suffered from heat stroke, many complained of serious leg cramps, and several had minor radiation burns on their faces.

Tough job. Takes tough men.

Sparks fly at school: Welding shop owner offers training course trying to meet growing demand

Is there a shortage of welders in your area? There is in Fargo, and here's what one woman did about it...

Deb Rubin decided to switch careers from medical instrument sterilizer to welder after playing around with a friend's wire welder. She's not the only one to launch a new career at a time when there's a shortage of welders in this part of the country.

"I went around to different shops in town to see what the demand was for welders. We found that there was high demand," Lynnes said. "We decided to open our own training center."

"We struggle to find qualified welders to hire," said Donette Peterson, human relations manager for Crary, a division of TerraMarc Industries that produces outdoor products, ag and potato equipment in West Fargo.

Sounds like a good idea to me!

Miller Releases Welding Safety Guides

I like what they're doing. All of these welder's safety guides are in PDF format, so you'll find them easy to print and keep handy.

Miller Welding's Welder's Safety Guides

To help you stay accident free, Miller is giving you a wide variety of welding safety guidelines and resources. These guidelines are based on AWS, ANSI, NEMA, NFPA, and many other organizations that have your best interests in mind. How does a pro use his tools? Safely and carefully - by the book - every day! Use these resources to join the ranks of professional welders whose lives depend on the safe handling and use of welding and cutting equipment.

These safety precautions contain the basic information needed to install, operate, maintain, and repair Miller welding equipment. They are short, direct, clear, and simple. These precautions are the backbone of every welder's Owner's Manual they produce. They cover most hazards you may encounter and explain briefly how to avoid them. Included at the end of each is a list of safety references so you can find more complete information if you need it.

Thanks to Miller for these invaluable guides. They'll make your welding safer and better.

They call it "Fallujah's Monster Garage."

A reminder that some welding jobs are more important than others...

"Sgt. David Liske of McCausland is a member of Combat Service Support Company 122 (CSSC-122), a unit which provides vehicle recovery and maintenance services for fellow Marines operating throughout western Iraq. A major task of the metalworkers is to weld additional armor onto Humvees and other military vehicles. "We're the guys who protect the rifle carriers and make sure they come home to their families," said Liske, the welding shop's noncommissioned officer in charge. "They want to come home to their families just like the rest of us." After arriving in Iraq last September, the unit's members worked around the clock to weld armor on more than 115 military vehicles used for convoys and patrols during the height of Fallujah combat operations."

Welcome to Welder's Corner

This is my first post on this blog -- and actually my first post on any blog. So bear with me. I'm here to look at welding, welder's issues, and welding equipment. I'll be looking at what the major welding manufacturers do, how-to guides for everyone from the hobbyist to the industrial career welder, and more...so here we go.